Gas diffuser assemblies for nozzle assemblies having multiple attachment methods

ABSTRACT

A welding torch having a nozzle assembly with multiple attachment methods is disclosed. The nozzle assembly includes a nozzle shell, an electrically insulating sleeve, and a nozzle insert. The nozzle insert is configured for attachment to gas diffuser assemblies with different attachment mechanisms (e.g. a slip-on mechanism relying on frictional force, and/or screw-on mechanism relying on torque).

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.62/626,763 filed Feb. 6, 2018, which is hereby incorporated by referencein its entirety.

TECHNICAL FIELD

The present disclosure generally relates to gas diffuser assemblies and,more particularly, to gas diffuser assemblies for nozzle assemblieshaving multiple attachment methods.

BACKGROUND

Conventional arc welding torches have a nozzle that attaches to a workend of the torch. The nozzle may attach to a removable component of thetorch (e.g. a gas diffuser, head, and/or nozzle holder of the torch),using one of several methods. Conventional nozzles and torches (and/orremovable components of the torch) are only configured for oneattachment method, and the attachment method of the removable componentand nozzle (and/or torch) must be coordinated in order to ensure secureattachment. To service customers and/or operators who have differentrequirements and/or preferences regarding the nozzle attachment methodused, manufacturers, suppliers, distributors, and/or operators must keeptrack of a large number of different parts in order to ensure properattachment and/or operation of the welding torch.

BRIEF SUMMARY

Systems and methods are provided for a nozzle assembly having multipleattachment methods, substantially as shown in and/or described inconnection with at least one of the figures, as set forth morecompletely in the claims.

These and other advantages, aspects and novel features of the presentinvention, as well as details of an illustrated example thereof, will bemore fully understood from the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an example of a metal inert gas (MIG) welding system with apower source and a wire feeder, in accordance with this disclosure.

FIG. 2 is a side view of an example of a welding torch of the MIGwelding system of FIG. 1, in accordance with this disclosure.

FIG. 3 is an exploded view of an example nozzle assembly.

FIG. 4a is a front perspective view of an example nozzle insert, inaccordance with this disclosure.

FIG. 4b is a rear perspective view of the example nozzle insert of FIG.4a , in accordance with this disclosure.

FIG. 4c is a cross-section view of the example nozzle insert of FIG. 4a, along the line 4 c-4 c, in accordance with this disclosure.

FIG. 5a is a front perspective view of an example slip-on gas diffuserassembly, in accordance with this disclosure.

FIG. 5b is a front perspective view of an example screw-on gas diffuserassembly, in accordance with this disclosure.

FIG. 5c is a front perspective view of an example slip-on gas diffuser,in accordance with this disclosure.

FIG. 5d is a front perspective view of an example screw-on gas diffuser,in accordance with this disclosure.

FIGS. 6a and 6b are perspective views of an example compressibleretaining ring, in accordance with this disclosure.

FIG. 7a is a partial cutaway view of an example nozzle assembly coupledto an example slip-on style gas diffuser assembly, in accordance withthis disclosure.

FIG. 7b is a partial cutaway view of an example nozzle assembly coupledto an example screw-on style gas diffuser assembly, in accordance withthis disclosure.

The figures are not necessarily to scale. Similar or identical referencenumerals may be used to refer to similar or identical components.

DETAILED DESCRIPTION OF THE INVENTION

Preferred examples of the present disclosure may be describedhereinbelow with reference to the accompanying drawings. In thefollowing description, well-known functions or constructions are notdescribed in detail because they may obscure the disclosure inunnecessary detail. For this disclosure, the following terms anddefinitions shall apply.

As utilized herein, “and/or” means any one or more of the items in thelist joined by “and/or”. As an example, “x and/or y” means any elementof the three-element set {(x), (y), (x, y)}. In other words, “x and/ory” means “one or both of x and y”. As another example, “x, y, and/or z”means any element of the seven-element set {(x), (y), (z), (x, y), (x,z), (y, z), (x, y, z)}. In other words, “x, y and/or z” means “one ormore of x, y and z”.

As utilized herein, the term “exemplary” means serving as a non-limitingexample, instance, or illustration. As utilized herein, the terms“e.g.,” and “for example” set off lists of one or more non-limitingexamples, instances, or illustrations.

The terms “coupled,” “coupled to,” and “coupled with” as used herein,each mean a structural and/or electrical connection, whether attached,affixed, connected, joined, fastened, linked, and/or otherwise secured.The term “attach” means to affix, couple, connect, join, fasten, link,and/or otherwise secure. The term “connect,” means to attach, affix,couple, join, fasten, link, and/or otherwise secure.

The terms “about” and/or “approximately,” when used to modify ordescribe a value (or range of values), position, orientation, and/oraction, mean reasonably close to that value, range of values, position,orientation, and/or action. Thus, the embodiments described herein arenot limited to only the recited values, ranges of values, positions,orientations, and/or actions but rather should include reasonablyworkable deviations.

As used herein, the terms “front” and/or “forward” refer to locationscloser to a welding arc, while “rear” refers to locations farther from awelding arc.

Some examples of the present disclosure relate to a gas diffuser,comprising a base comprising a groove configured to accept a retainingring, a nose having gas holes, a core coupling the base to the nose,where the core includes screw threads configured to engage complementaryscrew threads of the nozzle assembly, and a front shoulder positioned atan intersection of the core and the base, where the front shoulder isconfigured to abut a complementary shoulder of a nozzle assembly.

In some examples, the gas diffuser further comprises a bore extendingthrough an approximate center of the gas diffuser, where the gas holesare in fluid communication with the bore. In some examples, the grooveis positioned proximate the front shoulder. In some examples, the basecomprises a rear shoulder configured to abut a portion of the nozzleassembly. In some examples, the base further comprises a second grooveconfigured to accept an O-ring. In some examples, the base has a firstouter diameter that is larger than a second outer diameter of the core.In some examples, the nose has a third outer diameter that is smallerthan the second outer diameter of the core.

Some examples of the present disclosure relate to a gas diffuserassembly, comprising a gas diffuser comprising a base comprising aretaining ring groove configured to accept a retaining ring, a nosehaving gas holes, a core coupling the base to the nose, where the coreincludes screw threads configured to engage complementary screw threadsof the nozzle assembly, and a front shoulder positioned at anintersection of the core and the base, where the front shoulder isconfigured to abut a complementary shoulder of a nozzle assembly. Thegas diffuser assembly further comprises a retaining ring positionedwithin the retaining ring groove.

In some examples, the gas diffuser assembly further comprises a boreextending through an approximate center of the gas diffuser, where thegas holes are in fluid communication with the bore. In some examples,the gas diffuser assembly further comprises an O-ring positioned in anO-ring groove of the gas diffuser. In some examples, a rear shoulder ispositioned between the O-ring groove and the retaining ring groove. Insome examples, the retaining ring groove is positioned proximate thefront shoulder. In some examples, the base has a first outer diameterthat is larger than a second outer diameter of the core. In someexamples, the nose has a third outer diameter that is smaller than thesecond outer diameter of the core.

Some examples of the present disclosure relate to a welding torch,comprising a nozzle shell, a nozzle insert positioned within the nozzleshell, where the nozzle insert comprises an engaging surface configuredto frictionally engage a compressible member of a gas diffuser assembly,a threaded surface having screw threads to engage complementary screwthreads of the gas diffuser assembly, and a shoulder between the screwthreads and the engaging surface. The welding torch further comprises agas diffuser assembly coupled to the nozzle insert, where the gasdiffuser assembly comprises a gas diffuser, and wherein the gas diffusercomprises a base, a nose having gas holes, a core coupling the base tothe nose, and a front shoulder positioned at an intersection of the coreand the base, wherein the front shoulder abuts the shoulder of thenozzle insert.

In some examples, the gas diffuser assembly further comprises acompressible member positioned within a groove of the gas diffuser,where the compressible member frictionally engages the engaging surface.In some examples, the core is coupled to the nose through a taper, andan axial distance from an intersection of the taper and the nose to thefront shoulder is larger than or equal to an axial length of thethreaded surface. In some examples, the core includes screw threadsengaged to the threaded surface, where an axial distance from anintersection of the core and the nose to the compressible member isgreater than or equal to an axial length of the engaging surface. Insome examples, the nose extends out of the nozzle insert such that thegas holes are positioned outside of the nozzle insert. In some examples,the gas diffuser is coupled to a gooseneck.

Accommodating multiple types nozzle assemblies and gas diffuserassemblies (e.g., slip-on attachment, screw-on attachment, etc.) hascaused an increase in the inventories that manufacturers, distributors,and/or end users must maintain and/or manage Example nozzle assembliesdisclosed herein allow for a same nozzle to be attached to both aslip-on style gas diffuser (and/or head, nozzle holder, etc.) and ascrew-on style gas diffuser. Thus, disclosed nozzle assemblies obviatethe need for separate nozzles for each style. The example nozzle and gasdiffuser assemblies of the present disclosure would significantly reducethe amount of nozzle inventory a manufacturer, distributer, and/or enduser needs to maintain and/or manage.

A disclosed example nozzle assembly comprises three separate parts thatare secured together into a nozzle assembly: an outer shell, anelectrically insulating sleeve, and a nozzle insert. The nozzle insertof the disclosed example nozzle assembly is different from conventionalnozzle inserts in that the nozzle insert is capable of attachment toboth slip-on and screw-on style gas diffuser assemblies.

FIG. 1 shows an example of a metal inert gas (MIG) welding system 10that may use any of the example gas diffuser assemblies, nozzleassemblies, and/or other components discussed below. While the weldingsystem 10 is a MIG welding system, other types of welding systems may beused. FIG. 1 illustrates a welding system 10 as including a power source12 coupled to a wire feeder 14. In the illustrated example, the powersource 12 is separate from the wire feeder 14, such that the wire feeder14 may be positioned at some distance from the power source 12 near awelding location. However, it should be understood that the wire feeder14, in some implementations, may be integral with the power source 12.The power source 12 may supply weld power to a torch 16 through the wirefeeder 14, or the power source 12 may supply weld power directly to thetorch 16. The wire feeder 14 supplies a wire electrode 18 (e.g., solidwire, cored wire, coated wire) to the torch 16. A gas supply 20, whichmay be integral with or separate from the power source 12, supplies agas (e.g., CO₂, argon) to the torch 16. An operator may engage a trigger22 of the torch 16 to initiate an arc 24 between the electrode 18 and awork piece 26. In some examples, the welding system 10 may be triggeredby an automation interface including, but not limited to, a programmablelogic controller (PLC) or robot controller. The welding system 10 isdesigned to provide welding wire (e.g., electrode 18), weld power, andshielding gas to the welding torch 16. As will be appreciated by thoseskilled in the art, the welding torch 16 may be of many different types,and may facilitate use of various combinations of electrodes 18 andgases.

The welding system 10 may receive data settings from the operator via anoperator interface 28 provided on the power source 12. The operatorinterface 28 may be incorporated into a faceplate of the power source12, and may allow for selection of settings such as the weld process(e.g., stick, TIG, MIG), the type of electrode 18 to be used, voltageand current settings, transfer mode (e.g., short circuit, pulse, spray,pulse), and so forth. In particular, the welding system 10 allows forMIG welding (e.g., pulsed MIG welding) with electrodes 18 (e.g., weldingwires) of various materials, such as steel or aluminum, to be channeledthrough the torch 16. The weld settings are communicated to controlcircuitry 30 within the power source 12.

The control circuitry 30 operates to control generation of welding poweroutput that is applied to the electrode 18 by power conversion circuitry32 for carrying out the desired welding operation. For example, in someexamples, the control circuitry 30 may be adapted to regulate a pulsedMIG welding regime that may have aspects of short circuit transferand/or of spray transfer of molten metal from the welding wire to amolten weld pool of a progressing weld. Such transfer modes may becontrolled during operation by adjusting operating parameters of currentand voltage pulses for arcs 24 developed between the electrode 18 andthe work piece 26.

The control circuitry 30 is coupled to the power conversion circuitry32, which supplies the weld power (e.g., pulsed waveform) that isapplied to the electrode 18 at the torch 16. The power conversioncircuitry 32 is coupled to a source of electrical power as indicated byarrow 34. The power applied to the power conversion circuitry 32 mayoriginate in the power grid, although other sources of power may also beused, such as power generated by an engine-driven generator, batteries,fuel cells or other alternative sources. Components of the powerconversion circuitry 32 may include choppers, boost converters, buckconverters, inverters, and so forth.

The control circuitry 30 controls the current and/or the voltage of theweld power supplied to the torch 16. The control circuitry 30 maymonitor the current and/or voltage of the arc 24 based at least in parton one or more sensors 36 within the wire feeder 14 or torch 16. In someexamples, a processor 35 of the control circuitry 30 determines and/orcontrols the arc length or electrode extension based at least in part onfeedback from the sensors 36. The arc length is defined herein as thelength of the arc between the electrode 18 and the work piece 26. Theprocessor 35 determines and/or controls the arc length or electrodeextension utilizing data (e.g., algorithms, instructions, operatingpoints) stored in a memory 37. The data stored in the memory 37 may bereceived via the operator interface 28, a network connection, orpreloaded prior to assembly of the control circuitry 30. Operation ofthe power source 12 may be controlled in one or more modes, such as aconstant voltage (CV) regulation mode in which the control circuitry 30controls the weld voltage to be substantially constant while varying theweld current during a welding operation. That is, the weld current maybe based at least in part on the weld voltage. Additionally, or in thealternative, the power source 12 may be controlled in a current controlmode in which the weld current is controlled independent of the weldvoltage. In some examples, the power source 12 is controlled to operatein a constant current (CC) mode where the control circuitry 30 controlsthe weld current to be substantially constant while varying the weldvoltage during a welding operation.

FIG. 2 is a side view of an example of a welding torch 16 of the MIGwelding system of FIG. 1, which may use any of the example gas diffuserassemblies, nozzle assemblies, and/or other components discussed below.As discussed in relation to FIG. 1, the torch 16 includes the trigger 22for initiating a weld and supplying the electrode 18 to the weld.Specifically, the trigger 22 is disposed on a handle 38. A weldingoperator holds the handle 38 when performing a weld. At a first end 40,the handle 38 is coupled to a cable 42 where welding consumables (e.g.,the electrode, the shielding gas, and so forth) are supplied to theweld. Welding consumables generally travel through the handle 38 andexit at a second end 44, which is disposed on the handle 38 at an endopposite from the first end 40.

The torch 16 includes a gooseneck 46 extending out of the second end 44of the handle 38. As such, the gooseneck 46 is coupled between thehandle 38 and a welding nozzle 48. As should be noted, when the trigger22 is pressed or actuated, welding wire (e.g., electrode 18) travelsthrough the cable 42, the handle 38, the gooseneck 46, and the weldingnozzle 48, so that the welding wire extends out of an end 50 (i.e.,torch tip) of the welding nozzle 48. Further, as illustrated in FIG. 2,the handle 38 is secured to the gooseneck 46 via fasteners 52 and 54,and to the cable 42 via fasteners 52 and 54. The welding nozzle 48 isillustrated with a portion of the welding nozzle 48 removed to show theelectrode 18 extending out of a contact tip 56 that is disposed withinthe welding nozzle 48. While the example torch 16 illustrated in FIG. 2is designed for welding by a human operator, one or more torchesdesigned for use by a robotic welding system may alternatively, oradditionally, be used with the welding system of FIG. 1. For example,the torch 16 may be modified to omit the trigger 22, may be adapted forwater cooling, etc. The example torch 16 illustrated in FIG. 2 may alsobe used with any of the example gas diffuser assemblies, nozzleassemblies, and/or other components discussed below.

While conventional nozzle assemblies are configured to support and/orattach to only one or the other of slip-on or screw-on gas diffuserassemblies, the nozzle assembly 300 is configured to support bothslip-on and screw-on gas diffuser assemblies 500 a, 500 b. FIG. 3 showsan exploded view of the nozzle assembly 300. FIG. 7a shows the nozzleassembly 300 with a slip-on gas diffuser assembly 500 a. FIG. 7b showsthe nozzle assembly 300 with a screw-on gas diffuser assembly 500 b. Thecomponents of the nozzle assembly 300 and gas diffuser assemblies 500 a,500 b share an axis 100 when assembled and coupled together.

The nozzle assembly 300 includes a nozzle shell 302, an electricallyinsulating sleeve 304, and a nozzle insert 400. The nozzle shell 302 issubstantially hollow, with a bore extending through an approximatemiddle of the nozzle shell 302. The nozzle shell 302 includes asubstantially tubular rear portion 306 and a tapering front portion 308that narrows the outer and inner diameter of the nozzle shell 302. Asshown in FIGS. 7a and 7b , the nozzle shell 302 also includes a step 310on its inner wall that is configured to abut the electrically insulatingsleeve 304, so as to prevent the insulating sleeve 304 from proceedingfurther forward within the nozzle shell 302.

The electrically insulating sleeve 304 is positioned within the nozzleshell 302, between the nozzle shell 302 and the nozzle insert 400. Theelectrically insulating sleeve 304 is formed of electrically insulatingmaterial, so as to prevent electrical power conducted through gasdiffuser from being conducted to the nozzle shell 302, which may also beelectrically conductive in some examples. The electrically insulatingsleeve 304 extends along an inner surface of the nozzle shell 302. Theelectrically insulating sleeve 304 abuts the step 310 of the nozzleshell 302 proximate the transition from the tubular rear portion 306 tothe tapering front portion 308.

FIGS. 4a-4c show various views of the nozzle insert 400. The nozzleinsert 400 allows nozzle assembly 300 to support both screw-on andslip-on gas diffuser assemblies. In FIGS. 7a and 7b , the nozzle insert400 is positioned within the nozzle shell 302, adjacent the electricallyinsulating sleeve 304, approximately midway along the axial length ofthe nozzle shell 302. In some examples, the outer diameter of the nozzleinsert 400 may be approximately equal to an inner diameter of the nozzleshell 302 at the step 310 (or the inner diameter of the nozzle shell 302at its tubular rear portion 306 minus the thickness of the insulatingsleeve 304), such that the nozzle insert 400 fits snugly within thenozzle shell 302 and insulating sleeve 304. Because of the snug fit, thenozzle insert 400 may hold the insulating sleeve 304 in place againstthe nozzle shell 302. In some examples, the nozzle insert 400 isapproximately cylindrical, though in some examples the nozzle insert 400may be shaped differently to accommodate the shape of the nozzleassembly 300. The nozzle insert 400 includes a cylindrical wall 402surrounding a hollow interior. The nozzle insert 400 includes anengaging surface 404 formed on the inner wall 402 towards a rear end 406of the nozzle insert 400, and a threaded surface 408 formed in the wall402 towards a front end 410 of the nozzle insert 400. In some examples,this configuration may be reversed, such that the engaging surface 404is formed on the inner wall 402 towards the front end 410 of the nozzleinsert 400, and the threaded surface 408 is formed in the wall 402towards the rear end 406 of the nozzle insert 400.

The engaging surface 404 is configured to frictionally engage a gasdiffuser assembly, such as a slip-on gas diffuser assembly 500 a, forexample. In some examples, the frictional engaging surface 404 may alsofrictionally engage screw-on style gas diffusers 500 b. The engagingsurface has an axial length 404L. In some examples, the engaging surface404 may be formed with textures (e.g. knurls, bumps, etc.) configured toincrease frictional engagement between the engaging surface 404 and thegas diffuser assemblies 500 a, 500 b.

The threaded surface 408 includes female threaded grooves configured tothreadingly engage complementary male threads of a screw-on gas diffuserassembly 500 b. In some examples, the threaded surface 408 may beconfigured to simply pass over portions of slip-on style gas diffuserassemblies 500 a, without engaging, impeding, and/or inhibiting the gasdiffuser assemblies 500 a. The threaded surface 408 has an axial length408L.

The engaging surface 404 and threaded surface 408 of the nozzle insert400 are separated by a shoulder 412 formed in the wall 402. The shoulder412 is configured to abut a complementary front shoulder 512 of a gasdiffuser assembly 500 a, 500 b. While the outer diameter of the nozzleinsert 400 is relatively continuous along the axial length of the nozzleinsert 400, the inner diameter fluctuates. The inner diameter of thenozzle insert 400 along the axial length 404L of the engaging surface404 is larger than the major and minor inner diameters of the nozzleinsert 400 along the axial length 408L of the threaded surface 408. Insome examples, this configuration may be reversed, with the innerdiameter of the nozzle insert 400 along the axial length 404L of theengaging surface 404 being smaller than the major and minor innerdiameters of the nozzle insert 400 along the axial length 408L of thethreaded surface 408. The shoulder 412 of the nozzle insert 400 servesas the transition point of the inner diameter.

FIG. 5a shows a slip on style gas diffuser assembly 500 a. FIG. 7a showsa slip-on style gas diffuser assembly 500 a coupled to the nozzleassembly 300 via the nozzle insert 400 in accordance with aspects of thepresent disclosure. The gas diffuser assembly 500 a helps to guidewelding consumables (e.g., the electrode, the shielding gas, and soforth) within the nozzle assembly 300 of the welding torch 16. The gasdiffuser assembly 500 a includes a gas diffuser 502 a, a compressibleretaining ring 600, and an O-ring 504. In some examples, the gasdiffuser assembly 500 a may also include other components.

The gas diffuser 502 a is the primary component of the gas diffuserassembly 500 a. FIG. 5c shows an example gas diffuser 502 a for use withthe gas diffuser assembly 500 a. The gas diffuser 502 a acts as aninterface between the gooseneck 46 and the contact tip 56. The gasdiffuser 502 a is configured to transfer electrical energy to thecontact tip 56 (not shown) from the gooseneck 346 and transfer heatenergy from the contact tip 56 back into the gooseneck 46. While othercomponents may cooperate with the gas diffuser 502 a, the gas diffuser502 a provides the primary transmission path for heat and electricalcurrent between the contact tip 56 and the gooseneck 46. To increase theamount of electrical and heat energy transferred, the gas diffuser 502 amay be constructed using an electrically conductive and/or thermallyconductive material. A bore (and/or passage) extends through anapproximate middle (and/or center) of the gas diffuser 502 a. The boreextends from the front end 506 through to the rear end 508. The boreaccommodates movement of welding consumables (e.g. wire electrode 18and/or shielding gas) from the gooseneck 46 through the gas diffuser 502a and/or gas diffuser assembly 500 a.

In some examples, the gas diffuser 502 a includes a substantiallycylindrical base 510 towards the rear end 508 of the gas diffuser 502 aand a substantially cylindrical nose 514 towards the front end 506 ofthe gas diffuser 502 a. A substantially cylindrical central core 516 ispositioned between the nose 514 and the base 510. The central core 516connect to the base 510 at a front shoulder 512. The central core 516connects to the nose 514 through a taper 518. The base 510 has an outerdiameter that is larger than the outer diameter of the nose 514 and thecentral core 516. The central core 516 has an outer diameter that islarger than the outer diameter of the nose 514 and smaller than theouter diameter of the base 510. The base 510 may include an O-ringgroove 505 configured to receive an O-ring 504. In some examples, thebase 510 may also include a rear shoulder 513 configured to abut a rearend 406 of the nozzle insert 400 when the gas diffuser assembly 500 a iscoupled to the nozzle assembly 300.

In some examples, the gas diffuser 502 a may be configured to be coupledto the gooseneck 46 through the base 510 of the gas diffuser 502 a. Insome examples, the base 510 of the gas diffuser 502 a may includefeatures configured to frictionally engage the engaging surface 404 ofthe nozzle insert 400, so as to retain the gas diffuser 502 a within thenozzle assembly 300 and/or insert 400 using frictional force. In someexamples, these features may include ribs and/or protrusions (not shown)on the base 510 of the gas diffuser 502 a. In some examples, thefeatures may include a compressible member, such as a compressibleretaining ring 600, as shown, for example, in FIGS. 6a and 6b . In someexamples, the compressible retaining ring 600 may be constructed of aspring type material such that it generates a radially outward forceupon being compressed. In some examples, the retaining ring 600 may becompressed when coming into contact with the engaging surface 404, andgenerate a radially outward force against the engaging surface 404 so asto frictionally engage the engaging surface 404 and resist removal ofthe gas diffuser assembly 500 a from the nozzle insert 400. In someexamples, the retaining ring 600 may have protrusions 602 to increasefrictional engagement with the engaging surface. In some examples, thecompressible retaining ring 600 may be a non-sealing retention device,as opposed to an O-ring, for example, which is primarily a sealingdevice rather than a retention device. While conventional weldingtorches may include gas diffuser assemblies with O-rings that come intocontact with a nozzle and/or nozzle insert, these O-rings are primarilyused to create a gas seal, and lack the necessary radial force toprovide effective retention. The retaining ring 600 may be positionedwithin a ring groove 520 of the base 510 of the gas diffuser 502 a. Insome examples, the gas diffuser 502 a may include multiple ring grooves520, such that the retaining ring 600 may be repositioned on the gasdiffuser 502 a so as to accommodate different size nozzle inserts 400with different size and/or length engaging surfaces 404, for example.The ring groove 520 may be positioned proximate a front shoulder 512.

In some examples, the front shoulder 512 may serve a transition betweenthe base 510 of the gas diffuser 502 a and the central core 516 of thegas diffuser 502 a. In some examples, the core 516 of the gas diffuser502 a may be substantially smooth. In some examples, the outer diameterof the core 516 is sized so as to be able to fit within and/or slidethrough the bore of the nozzle insert 400 proximate the engaging surface404 and threaded surface 408 without contacting and/or frictionallyengaging the engaging surface 404 and/or threaded surface 408. The taper518 connects the core 516 to the nose 514.

The nose 514 of the gas diffuser 502 a is configured for attachment to acontact tip (not shown). The nose 514 includes gas holes 522 to allowgas to diffuse from within the bore of the gas diffuser 502 a, throughthe gas holes 522, and into the interior of the nozzle shell 302. Thenose 514 has an outer diameter that is smaller than the base 510 andcore 516, such that the nose 514 may not engage or contact the nozzleinsert 400 when the gas diffuser assembly 500 a, 500 b is coupled to thenozzle insert 400. In some examples, an axial distance from theintersection of the taper 518 and nose 514 to the front shoulder 512 maybe larger than or equal to the axial length 408L of the threaded surface408 of the nozzle insert 400. In some examples, an axial length of thecore 516 may be approximately equal to the axial length 408L of thethreaded surface 408 of the nozzle insert 400. This may help ensure thatthe nose 514 of the gas diffuser 502 a extends outside of the nozzleinsert 400, and the gas holes 522 of the nose 514 are positioned outsideof and/or away from the nozzle insert 400 during operation.

FIG. 5b shows an example screw-on (and/or thread-on) style gas diffuserassembly 500 b. FIG. 5d shows a screw-on (and/or thread-on) style gasdiffuser 502 b in accordance with aspects of the present disclosure.FIG. 7b shows a screw-on style gas diffuser assembly 500 b coupled tothe nozzle assembly 300 via the nozzle insert 400 in accordance withaspects of the present disclosure. In some examples, the screw-on gasdiffuser assembly 500 b may be similar in most aspects with the slip-ongas diffuser assembly 500 a. However, in some examples, the screw-on gasdiffuser 502 b may not have a taper 518 connecting the core 516 to thenose 514. Also, the core 516 may not be substantially smooth. Rather, insome examples, the central core 516 may be threaded with male screwthreads 524 configured to threadingly engage the female threaded groovesof the threaded surface 408 of the nozzle insert 400. Torque between thethreaded surface 408 of the nozzle insert 400 and the male screw threads524 of the core 516 of the gas diffuser assembly 500 b holds the gasdiffuser assembly 500 b in place within the nozzle shell 302 and/ornozzle insert 400. In some examples, the axial distance from a firstscrew thread (and/or the intersection of the nose 514 and core 516) tothe compressing retaining ring 600 of the screw-on gas diffuser assembly500 b may be greater than or equal to the axial length 404L of theengaging surface 404 of the nozzle insert 400. In such an example, thethreads 524 of the core 516 of the gas diffuser 502 b will begin toengage with the threaded surface 408 of the nozzle insert 400 before (orat substantially the same time as) the engaging surface 404 comes intocontact with the compressible retaining ring 600. This may help toprevent frictional forces between the retaining ring 600 and theengaging surface 404 from resisting insertion of the gas diffuserassembly 500 b into the nozzle insert 400 before it is possible to beginscrewing the nozzle insert 400 onto the gas diffuser assembly 500 b.

FIGS. 7a and 7b show slip-on and screw-on style gas diffuser assemblies500 a, 500 b coupled to the nozzle assembly 300 via the nozzle insert400 in accordance with aspects of the present disclosure. In operation,an operator may assemble a nozzle assembly 300 using one of the screw-ongas diffuser assembly 500 b, or slip-on gas diffuser assembly 500 a,according to operator preference. If an operator wishes to use theslip-on gas diffuser assembly 500 a, for example, the operator may takethe nozzle shell 302 (with the insulating sleeve 304 and nozzle insert400 snugly fit within) and push the slip-on gas diffuser assembly 500 athrough a rear end of the nozzle shell 302 into the nozzle insert 400.The operator may be able to push the nose 514 and core 516 of the gasdiffuser assembly 500 a through the insert with minimal friction and/orresistance because the nose 514 and core 516 of the gas diffuserassembly 500 a, being slimmer with smaller outer diameters, will slidethrough the nozzle insert 400 without engaging. Eventually though, thebase 510 of the gas diffuser assembly 500 a will contact the engagingsurface 404 of the nozzle insert 400, causing friction and/orresistance, after which more effort may be needed to push the gasdiffuser assembly 500 a into the nozzle insert 400. After someadditional effort, the operator may push the gas diffuser assembly 500 ain far enough that the retaining ring 600 is compressed by the engagingsurface 404, providing additional radially outward force against theengaging surface 404, and increasing the friction and/or resistance.Finally, when the front shoulder 512 of the gas diffuser assembly 500 aabuts the shoulder 412 of the nozzle insert 400 and/or the rear shoulder513 of the gas diffuser assembly 500 a abuts the rear end 406 of thenozzle insert 400, the operator will have pushed the gas diffuserassembly 500 a in as far as possible. Thereafter, the operator mayproceed with normal operation, confident that frictional forces betweenthe engaging surface 404 and gas diffuser assembly 500 a would retainthe gas diffuser assembly 500 a securely within the nozzle shell 302and/or nozzle insert 400.

If, for example, the operator wished to replace the slip-on gas diffuserassembly 500 a with the screw-on gas diffuser assembly 500 b, theoperator may first remove the slip-on gas diffuser assembly 500 a bypulling the slip-on gas diffuser assembly 500 a out of the nozzle insert400. Some force may be needed to overcome the frictional force holdingthe slip-on gas diffuser assembly 500 a in place. Once the slip-on gasdiffuser assembly 500 a has been removed, the operator may take the samenozzle shell 302 (with the insulating sleeve 304 and nozzle insert 400still snugly fit within) and push the screw-on gas diffuser assembly 500b through the rear end of the nozzle shell 302 into the nozzle insert400. The operator may be able to push the nose 514 of the gas diffuserassembly 500 b through the insert with minimal friction and/orresistance because the nose 514 of the gas diffuser assembly 500 b,being slimmer with a smaller outer diameter, will slide through thenozzle insert 400 without engaging. Eventually though, the male screwthreads 524 of the central core 516 of the screw-on gas diffuserassembly 500 b will contact the complementary female threaded grooves ofthe threaded surface 408 of the nozzle insert 400. Once this occurs, theoperator may rotate the screw-on gas diffuser assembly 500 b to screwthe male screw threads 524 of the central core 516 of the screw-on gasdiffuser assembly 500 b into the complementary female threaded groovesof the threaded surface 408 of the nozzle insert 400. While the operatoris screwing the screw-on gas diffuser assembly 500 b into the nozzleinsert 400, the base 510 and/or compressible retaining ring 600 maybegin to come into contact with the engaging surface 404 of the nozzleinsert 400, increasing friction and/or resistance. Finally, when thefront shoulder 512 of the gas diffuser assembly 500 b abuts the shoulder412 of the nozzle insert 400 and/or the rear shoulder 513 of the gasdiffuser assembly 500 a abuts the rear end 406 of the nozzle insert 400,the operator will have securely screwed the gas diffuser assembly 500 b.Thereafter, the operator may proceed with normal operation, while thetorque of the screw threads and frictional forces between the nozzleinsert 400 and gas diffuser assembly 500 b retains the gas diffuserassembly 500 b securely within the nozzle shell 302 and/or nozzle insert400.

Notably, with the screw-on gas diffuser assembly 500 b, both the torqueof the screw threads and the frictional forces between the compressibleretaining ring 600 and engaging surface 402 help to retain the gasdiffuser assembly 500 b within the nozzle assembly 300 and resistloosening and/or disengagement. This is in contrast with conventionalscrew on gas diffuser assemblies that rely exclusively on the torque ofthe screw threads for retention. The dual engagement features of thescrew-on gas diffuser assembly 500 b and nozzle assembly 300 counteractthe multitude of stresses that may induce loosening and/or disengagementduring welding operation (e.g. vibrations, collisions, abrasions,deformations, snags, scrapes, etc.) better than the single engagementfeature of conventional screw-on gas diffuser assemblies. Also, sincethere is no need to change to a different nozzle shell 302 and/or nozzleinsert 400 to accommodate the screw-on gas diffuser assembly 500 b orslip-on gas diffuser assembly 500 a, the operator may save valuable timeand/or resources.

While the above operation is described as pushing the gas differassembly 500 a, 500 b into the nozzle shell 302, in some examples anoperator may instead push the nozzle shell 302 (and/or insulating sleeve304 and/or nozzle insert 400) onto the gas diffuser assembly 500 a, 500b. In some examples, the gas diffuser assembly 500 a, 500 b may alreadybe attached to the gooseneck 46 and/or contact tip before and/or afterbeing assembled onto the nozzle shell 302 (and/or insulating sleeve 304and/or nozzle insert 400). In some examples, other components may alsobe used with the nozzle assembly 300 in operation (e.g. liner, linerguide, etc.).

While the present method and/or system has been described with referenceto certain implementations, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted without departing from the scope of the present methodand/or system. For example, block and/or components of disclosedexamples may be combined, divided, re-arranged, and/or otherwisemodified. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from its scope. Therefore, the presentmethod and/or system are not limited to the particular implementationsdisclosed. Instead, the present method and/or system will include allimplementations falling within the scope of the appended claims, bothliterally and under the doctrine of equivalents.

What is claimed is:
 1. A gas diffuser, comprising: a base comprising afirst groove configured to accept a retaining ring, and a second grooveconfigured to accept an O-ring; a nose having gas holes; a core couplingthe base to the nose, wherein the core includes screw threads configuredto engage complementary screw threads of a nozzle assembly; and a frontshoulder positioned at an intersection of the core and the base, whereinthe front shoulder is configured to abut a complementary shoulder of thenozzle assembly, the base has a first outer diameter that is larger thana second outer diameter of the core, the nose has a third outer diameterthat is smaller than the second outer diameter of the core, and thefront shoulder has a diameter that is smaller than the first outerdiameter of the base and larger than the second outer diameter of thecore and the third outer diameter of the nose.
 2. The gas diffuser ofclaim 1, further comprising a bore extending through an approximatecenter of the gas diffuser, wherein the gas holes are in fluidcommunication with the bore.
 3. The gas diffuser of claim 1, wherein thefirst groove is positioned proximate the front shoulder.
 4. The gasdiffuser of claim 1, wherein the base comprises a rear shoulderconfigured to abut a portion of the nozzle assembly.
 5. The gas diffuserof claim 4, wherein the rear shoulder is between the first groove andthe second groove.
 6. The gas diffuser of claim 1, wherein the base,core, or nose is cylindrical.
 7. The gas diffuser of claim 1, whereinthe first groove and the second groove comprises a depressed surfacebounded on two sides by raised surfaces.
 8. A gas diffuser assembly,comprising: a gas diffuser comprising: a base comprising a retainingring groove configured to accept a retaining ring, a nose having gasholes, a core coupling the base to the nose, wherein the core includesscrew threads configured to engage complementary screw threads of anozzle assembly, and a front shoulder positioned at an intersection ofthe core and the base, wherein the front shoulder is configured to abuta complementary shoulder of the nozzle assembly, the base has a firstouter diameter that is larger than a second outer diameter of the core,the nose has a third outer diameter that is smaller than the secondouter diameter of the core, and the front shoulder has a diameter thatis smaller than the first outer diameter of the base and larger than thesecond outer diameter of the core and the third outer diameter of thenose; and a retaining ring positioned within the retaining ring groove.9. The gas diffuser assembly of claim 8, further comprising a boreextending through an approximate center of the gas diffuser, wherein thegas holes are in fluid communication with the bore.
 10. The gas diffuserassembly of claim 8, further comprising an O-ring positioned in anO-ring groove of the gas diffuser.
 11. The gas diffuser assembly ofclaim 10, wherein a rear shoulder is positioned between the O-ringgroove and the retaining ring groove.
 12. The gas diffuser assembly ofclaim 8, wherein the retaining ring groove is positioned proximate thefront shoulder.
 13. The gas diffuser assembly of claim 8, wherein thebase, core, or nose is cylindrical.
 14. The gas diffuser assembly ofclaim 8, wherein the base, core, and nose are cylindrical.
 15. A weldingtorch, comprising: a nozzle shell; a nozzle insert positioned within thenozzle shell, wherein the nozzle insert comprises an engaging surfaceconfigured to frictionally engage a compressible member of a gasdiffuser assembly, a threaded surface having screw threads to engagecomplementary screw threads of a gas diffuser assembly, and a shoulderbetween the screw threads and the engaging surface; and the gas diffuserassembly coupled to the nozzle insert, wherein the gas diffuser assemblycomprises a gas diffuser, and wherein the gas diffuser comprises: abase, a nose having gas holes, wherein the nose extends out of thenozzle insert such that the gas holes are positioned outside of thenozzle insert, a core coupling the base to the nose, and a frontshoulder positioned at an intersection of the core and the base, whereinthe front shoulder abuts the shoulder of the nozzle insert.
 16. Thewelding torch of claim 15, wherein the gas diffuser assembly furthercomprises the compressible member positioned within a groove of the gasdiffuser, and wherein the compressible member frictionally engages theengaging surface.
 17. The welding torch of claim 15, wherein the core iscoupled to the nose through a taper, and wherein an axial distance froman intersection of the taper and the nose to the front shoulder islarger than or equal to an axial length of the threaded surface.
 18. Thewelding torch of claim 15, wherein the core includes screw threadsengaged to the threaded surface, wherein an axial distance from anintersection of the core and the nose to the compressible member isgreater than or equal to an axial length of the engaging surface. 19.The welding torch of claim 15, wherein an axial length of the core ofthe gas diffuser is equal to an axial length of the threaded surface ofthe nozzle insert.
 20. The welding torch of claim 15, wherein the gasdiffuser is coupled to a gooseneck.